Sole structure and method of making the same

ABSTRACT

A sole structure includes a soft body, a hard inner layer member, and a plurality of soft engaging members; wherein the body is made of soft-fiber composite materials without adding thermoset epoxy resin (such as carbon fiber/glass fiber) and formed in a laminate sole shape with a peripheral member, on a bottom surface of the body are formed a plurality of holes; the hard inner layer member is made of engineering plastics and fixed to the bottom surface of the body and includes a number of apertures in response to the holes; the soft engaging members are injection molded from soft composite materials (such as TPU, TPR, etc.) and integrally coupled with the hard inner layer member on the body, such that the soft body, the hard inner layer member, and the soft engaging members are integrally coupled together to form the sole structure.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a sole structure, and more particularly to a sole structure and method of making the same adopted for bicycles.

2. Description of the Prior Art

Conventional sole structure adopted for racing or mountain bicycles is made of hard plastic or carbon fiber materials to engage with a fastening member, thus stepping a pedal securely during riding.

However, such convention sole structure is heavy and not strength enough. To solve such a problem, an improved sole structure has been developed. The improved sole structure is made of carbon fiber materials with epoxy resin and covered by using multi-layer hardening form method, causing disengagement of the sole structure from uppers of a shoe easily.

SUMMARY OF THE INVENTION

The primary object of the present invention is to provide a sole structure that is made easily and massively.

Further object of the present invention is to provide a sole structure that can be lowered weight and enhanced strength.

Another object of the present invention is to provide a sole structure that can prevent the sole structure from disengagement from uppers.

A sole structure in accordance with the present invention comprises:

a soft body, a hard inner layer member, and a plurality of soft engaging members; wherein the body is made of soft-fiber composite materials without adding thermoset epoxy resin (such as carbon fiber/glass fiber) and formed in a laminate sole shape with a peripheral member, on a bottom surface of the body are formed a plurality of holes; the inner layer member is made of engineering plastics and fixed to the bottom surface of the body and includes a number of apertures in response to the holes; the engaging members are injection molded from soft composite materials (such as TPU, TPR, etc.) and integrally coupled with the inner layer member on the body, such that the soft body, the hard inner layer member, and the soft engaging members are integrally coupled together to form the sole structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view showing a sole structure adopted for a shoe of racing bicycles in accordance with a first embodiment of the present invention;

FIG. 2 is an exploded view showing a sole structure adopted for a shoe of mountain bicycles in accordance with a second embodiment of the present invention;

FIG. 3 is a cross sectional view showing the assembly of the sole structure adopted for the shoe of racing bicycles in accordance with the first embodiment of the present invention;

FIG. 4 is a cross sectional view showing the assembly of the sole structure adopted for the shoe of mountain bicycles in accordance with the second embodiment of the present invention;

FIG. 5 is a perspective view showing the operation of the sole structure adopted for the shoe of racing bicycles in accordance with the embodiment of the present invention;

FIG. 6 is a perspective view showing the operation of the sole structure adopted for the shoe of mountain bicycles in accordance with the first embodiment of the present invention;

FIG. 7 is a flow chart of the sole structure showing the manufacturing processes in accordance with the first and second embodiments of the present invention;

FIG. 8 is an exploded view showing a sole structure adopted for a shoe of racing bicycles in accordance with a third embodiment of the present invention;

FIG. 9 is an exploded view showing a sole structure adopted for a shoe of mountain bicycles in accordance with a fourth embodiment of the present invention;

FIG. 10 is a cross sectional view showing the assembly of the sole structure adopted for the shoe of racing bicycles in accordance with the third embodiment of the present invention;

FIG. 11 is a cross sectional view showing the assembly of the sole structure adopted for the shoe of mountain bicycles in accordance with the fourth embodiment of the present invention;

FIG. 12 is a flow chart of the sole structure showing a method of making a sole structure in accordance with the third and fourth embodiments of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will be clearer from the following description when viewed together with the accompanying drawings, which show, for purpose of illustrations only, the preferred embodiment in accordance with the present invention.

Referring to FIGS. 1 and 2, which are exploded views of a sole structure 1 adopted for a shoe of racing bicycles and a sole structure 2 adopted for a shoe of mountain bicycles respectively in accordance with a first and a second embodiments of the present invention respectively, the sole structures 1, 2 comprise soft bodies 11, 21, hard inner layer members 12, 22, and a plurality of soft engaging members 13, 23 made of composite materials individually, wherein

the bodies 11, 21 are made of soft-fiber composite materials without adding thermoset epoxy resin (such as carbon fiber/glass fiber) and formed in a laminate sole shape with peripheral members 110, 210 respectively, on bottom surfaces 111, 211 of the bodies 11, 21 are formed a plurality of holes 112, 212 for engaging with fastening members (not shown) and a number of openings 113, 213 for connection with the engaging members 13, 23 individually;

the hard inner layer members 12, 22 are made of engineering plastics and fixed to the bottom surfaces 111, 211 of the bodies 11, 21 and include a number of apertures 120, 220 in response to the holes 112, 212 individually;

the engaging members 13, 23 are injection molded from soft composite materials (such as TPU, TPR, etc.) and integrally coupled with the inner layer members 12, 22 on front and rear portions of the bottom surfaces 111, 211 of the bodies 11, 21 (e.g. a sole structure for a shoe of racing bicycles) or around outer rims of the bodies 11, 21 (e.g. a sole structure for a shoe of mountain bicycles) respectively.

The assembling processes of the sole structure according to the first and the second embodiments of the present invention include: putting the bodies 11, 21 and the engaging members 13, 23 into a mold and then injection molding the inner layer members 12, 22 from the mold to the bottom surfaces 111, 211 of the bodies 11, 21 respectively so as to form integrally formed sole structures 1, 2 (as illustrated in FIGS. 3 and 4).

Referring further to FIG. 7, a method of making a sole structure according to the abovementioned embodiments of the present invention includes:

a. making soft-fiber composite materials into a laminate body with a peripheral member and arranging a plurality of holes for engagement with a fastening member (not shown) and openings for connection with a plurality of engaging members on a bottom surface of a sole structure individually;

b. making the engaging members from soft composite materials;

c. putting the body and the engaging members into the mold;

d. injection molding a hard inner layer member which is made of engineering plastics from the mold to an inner end surface of the body and then injection molding the openings and the engaging members together to the body, thereby forming the sole structure.

Because the sole structure made is to apply soft-fiber composite materials without adding thermoset epoxy resin to form the body, and the inner layer member made from hard composite materials is injection molded to the body, the hard bottom surface is formed and the peripheral member of the body owns flexible toughness, thereby the body adheres with an uppers A easily (as shown in FIGS. 5 and 6). Besides, a connecting seam is formed on a shoe edge so as to connect the sole structure and the uppers securely. Also, the openings are arranged on the bottom surface of the body, thus injection molding the soft composite materials relative to the openings onto an outer end surface of the body simultaneously.

With reference to FIGS. 8-10, which are exploded views of a sole structure 3 adopted for a shoe of racing bicycles and a sole structure 4 adopted for a shoe of mountain bicycles respectively in accordance with a third and a fourth embodiments of the present invention, the sole structures 3, 4 comprise soft bodies 31, 41, hard inner layer members 32, 42, and a plurality of soft engaging members 33, 43 made of composite materials respectively, wherein

the bodies 31, 41 are made of soft-fiber composite materials without adding thermoset epoxy resin (such as carbon fiber/glass fiber) and formed in a laminate sole shape with peripheral members 310, 410 individually, on bottom surfaces 311, 411 of the bodies 31, 41 are formed a plurality of holes 312, 412 for engaging with fastening members (not shown) respectively;

the hard inner layer members 32, 42 are made of engineering plastics and fixed to the bottom surfaces 311, 411 of the bodies 31, 41 and include a number of apertures 320, 420 in response to the holes 312, 412 individually;

the engaging members 33, 43 are injection molded from soft composite materials (such as TPU, TPR, etc.) and integrally coupled on front and rear portions of the bottom surfaces 311, 411 of the bodies 31, 41 (e.g. a sole structure for a shoe of racing bicycles) or around outer rims of the bodies 31, 41 (e.g. a sole structure for a shoe of mountain bicycles).

The assembling processes of the present invention include: putting the bodies 31, 41 and the engaging members 33, 43 into a mold simultaneously and then injecting the engaging members 33, 34 from the mold to integrally couple with the bodies 31, 41 individually; putting the integrally coupled bodies and engaging members to another mold; injecting the inner layer members 32, 42 to the bottom surfaces 311, 411 of the bodies 31, 41 so as to form integrally formed sole structures 3, 4.

FIG. 12 is a flow chart showing a method of making a sole structure according to the third and the fourth embodiments of the present invention, and because the soft-fabric composite materials include surfactant coated on a surface thereof to connect with the soft composite materials (such as TPU, TPR etc.) and the hard engineering plastics by injection, achieve the following manufacturing steps:

a. forming soft-fiber composite materials to a laminate body with a peripheral member and arranging a plurality of holes on a bottom surface of a sole structure for engagement with a fastening member (not shown);

b. putting the body into a mold;

c. injecting a plurality of engaging members from the mold to an outer end surface of the body so as to integrally form the engaging members and the body.

d. putting the integrally formed body and engaging members into another mold;

e. injecting an inner layer member from the mold to an inner end surface of the body so that the inner layer member is integrally formed with the body, thus forming a sole structure.

It is apparent form the above description that the present invention has the following advantages:

1. Easy and mass manufacture: because the body is made of soft-fiber composite materials without adding thermoset epoxy resin and the hard inner layer member made of engineering plastics is injection molded, manufacturing the sole structure easily and massively.

2. Lower production cost: since the sole structure of the present invention can be manufactured massively, lowering production cost.

3. Excellent strength: due to the hard inner layer member made of the engineering plastics is injected molded to the inner end surface of the body which is made of soft fabric composite materials, the inner layer member can be completely fixed after it is coupled with the uppers, preventing the inner layer member from disengagement from the uppers.

While we have shown and described various embodiments in accordance with the present invention, it is clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention. 

1. A sole structure comprising: a soft body, a hard inner layer member, and a plurality of soft engaging members; wherein the body is made of soft-fiber composite materials without adding thermoset epoxy resin and formed in a laminate sole shape with a peripheral member, on a bottom surface of the body are formed a plurality of holes; the hard inner layer member is made of engineering plastics and fixed to the bottom surface of the body and includes a number of apertures in response to the holes; the soft engaging members are injection molded from soft composite materials and integrally coupled with the hard inner layer member on the body.
 2. The sole structure as claimed in claim 1, wherein the soft-fiber composite materials are selected from carbon fiber and glass fabric
 3. The sole structure as claimed in claim 1, wherein the composite materials made into the soft engaging member are selected from TPU and TPR.
 4. The sole structure as claimed in claim 1, wherein on connecting portions of the body and the engaging members are arranged a plurality of apertures.
 5. The sole structure as claimed in claim 1, wherein the engaging members are fixed on front and rear portions of the bottom surface of the body.
 6. The sole structure as claimed in claim 1, wherein the engaging members are fixed on front and rear portions of the bottom surface of the body.
 7. A method of making a sole structure comprising: a. making soft-fiber composite materials into a laminate body with a peripheral member and arranging a plurality of holes and openings on a bottom surface of a sole structure; b. making the engaging members from soft composite materials; c. putting the body and the engaging members into the mold; d. injection molding a hard inner layer member which is made of engineering plastics from the mold to an inner end surface of the body and then injection molding the openings and the engaging members together to the body, thereby forming the sole structure.
 8. A method of making a sole structure comprising: a. forming soft-fiber composite materials to a laminate body with a peripheral member and arranging a plurality of holes on a bottom surface of a sole structure; b. putting the body into a mold; c. injecting a plurality of engaging members from the mold to an outer end surface of the body so as to integrally form the engaging members and the body. d. putting the integrally formed body and engaging members into another mold; e. injecting an inner layer member from the mold to an inner end surface of the body so that the inner layer member is integrally formed with the body, thus forming a sole structure. 